Case Study: Custom Unisex Outdoor Cap for a Military Supply Unit in Spain
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Military Supply Unit in Spain
A Military Supply Unit approached us with a unisex outdoor cap requirement for Spain. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive shipping and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- Suppliers who disappear once the deposit is paid
- No reliable way to track a order once it enters production
- Color drift between lab dips and bulk fabric
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A Military Supply Unit |
| Market | Spain |
| Order volume | 2,000 pieces across 6 colourways |
| Base fabric | Moisture-Wicking Knit |
| Decoration | Laser Cutting |
| Size range | 2-12Y |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Moisture-Wicking Knit and locked shrinkage allowance before grading.
- Decoration was moved to Laser Cutting after strike-off tests showed better wash durability.
- A pre-production sample was approved and retained as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and size ratio specification.
Result
- 2,000 pieces delivered inside the 5-week window.
- Unit cost held within 3.0% of the original quotation.
- Return rate linked to fit or workmanship stayed under 1.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Approve a pre-production sample from the actual bulk fabric. Proto cloth behaves differently in cutting and washing.
Planning something similar?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
